Flow control devices including materials containing hydrophilic surfaces and related methods

Abstract

Flow control devices for regulating fluid flow from a subterranean formation by utilizing materials containing hydrophilic surfaces in a flow path of formation fluids. The flow control device comprises a tubular body, a flow path, and a material having a hydrophilic surface disposed within the flow path to restrict the flow of water. Methods of making and systems utilizing the flow control devices are disclosed.

What is claimed is: 
     
       1. A flow control device for selectively controlling fluid flow from a subterranean formation, comprising:
 a first tubular body having an interior surface, an exterior surface, and at least one aperture comprising an inlet extending through the first tubular body between the exterior surface and the interior surface; 
 a second tubular body located within the first tubular body, the second tubular body having an interior surface, an exterior surface, and at least another aperture comprising an outlet extending through the second tubular body between the exterior surface and the interior surface; 
 an annular cavity defined by the interior surface of the first tubular body and the exterior surface of the second tubular body; 
 at least one flow path extending from the exterior surface and through the inlet of the first tubular body, longitudinally through the annular cavity, and to the interior surface through the outlet of the second tubular body; and 
 a material disposed in communication with the at least one flow path, the material having a hydrophilic surface located and configured to contact formation fluids flowing along the at least one flow path, wherein at least a portion of the material is disposed within the annular cavity, the material having a composition enabling flow of hydrocarbons through the material while restricting the flow of water through the material while maintaining a constant flow area of the at least one flow path. 
 
     
     
       2. The flow control device of  claim 1 , wherein the first tubular body comprises at least one filter located exterior to the material, the at least one filter configured to filter particulates from the formation fluids. 
     
     
       3. The flow control device of  claim 2 , wherein the material disposed in communication with the at least one flow path comprises a plurality of particles disposed between the at least one filter and the second tubular body. 
     
     
       4. The flow control device of  claim 3 , wherein the plurality of particles comprises at least one of quartz sand, flint, agate, porous glass, and glass beads. 
     
     
       5. The flow control device of  claim 1 , wherein the material disposed in communication with the at least one flow path comprises a tubular sleeve. 
     
     
       6. The flow control device of  claim 1 , wherein the material disposed in communication with the at least one flow path comprises a coating applied to a surface of the material disposed in communication with the at least one flow path. 
     
     
       7. The flow control device of  claim 6 , wherein the surface of the material disposed in communication with the at least one flow path comprises at least one of a channel, tube, orifice, port, and opening. 
     
     
       8. The flow control device of  claim 1 , wherein the material having the hydrophilic surface is selected from a group consisting of silicon dioxide (SiO 2 ) and surface-modified silicon dioxide. 
     
     
       9. The flow control device of  claim 1 , wherein the material having the hydrophilic surface comprises at least one of titanium dioxide (TiO 2 ) doped composites and ceramic-based composites. 
     
     
       10. A method for making a flow control device to selectively control fluid flow from a subterranean formation, the method comprising:
 providing a first tubular body having an interior surface, an exterior surface, and at least one aperture comprising an inlet extending through the first tubular body between the exterior surface and the interior surface; 
 providing a second tubular body located within the first tubular body, the second tubular body having an interior surface, an exterior surface, and at least another aperture comprising an outlet extending through the second tubular body between the exterior surface and the interior surface; 
 defining an annular cavity with the interior surface of the first tubular body and the exterior surface of the second tubular body; 
 defining at least one flow path extending from the exterior surface and through the inlet of the first tubular body, longitudinally through the annular cavity, and to the interior surface through the outlet of the second tubular body; 
 configuring a material having a hydrophilic surface to allow passage of hydrocarbons through the material while restricting the flow of water through the material while maintaining a constant flow area of the at least one flow path; 
 disposing the material having the hydrophilic surface in communication with the at least one flow path, at least a portion of the material being disposed within the annular cavity; and 
 saturating at least a portion of the material with an initial amount of water. 
 
     
     
       11. The method of  claim 10 , further comprising positioning at least one of a filter, a mesh, and a permeable membrane exterior to the material. 
     
     
       12. The method of  claim 10 , wherein disposing the material in communication with the at least one flow path further comprises placing the material along the interior surface of the first tubular body. 
     
     
       13. A system for selectively controlling flow of a fluid from a subterranean formation, comprising:
 at least one wellbore tubular; 
 a first tubular body positioned adjacent the at least one wellbore tubular, the first tubular body having an interior surface, an exterior surface, and at least one aperture comprising an inlet extending through the first tubular body between the exterior surface and the interior surface; 
 a second tubular body located within the first tubular body, the second tubular body having an interior surface, an exterior surface, and at least another aperture comprising an outlet extending through the second tubular body between the exterior surface and the interior surface; 
 an annular cavity defined by the interior surface of the first tubular body and the exterior surface of the second tubular body; 
 the first tubular body and the second tubular body defining at least one flow path extending through the inlet of the first tubular body, longitudinally through the annular cavity, and through the outlet of the second tubular body; and 
 a material disposed in communication with the at least one flow path, the material comprising at least a hydrophilic surface located and configured to contact formation fluids flowing along the at least one flow path, at least a portion of the material being disposed within the annular cavity, wherein the material is configured to allow passage of oil-based formation fluids through the material while restricting the flow of water-based fluids through the material while maintaining a constant flow area of the at least one flow path. 
 
     
     
       14. The system of  claim 13 , wherein the first tubular body is located adjacent at least one perforation in the at least one wellbore tubular proximate at least one production zone prone to water production. 
     
     
       15. The system of  claim 13 , wherein the material disposed in communication with the at least one flow path comprises a plurality of discrete particles within a packet at least partially filling the at least one flow path. 
     
     
       16. The system of  claim 13 , wherein the material disposed in communication with the at least one flow path comprises a filter mesh at least partially obstructing the at least one flow path. 
     
     
       17. The system of  claim 13 , wherein the material disposed in communication with the at least one flow path comprises a coating applied to a surface of at least one flow control device having a tortuous pathway adjacent the at least one flow path. 
     
     
       18. The system of  claim 13 , wherein the material disposed in communication with the at least one flow path is positioned down a length of the first tubular body and further comprising a screen disposed exterior to the material along the length of the first tubular body.